Self-cleaning substrates and methods for making the same

• US 8,617,665 B2
• Filed: 09/29/2009
• Issued: 12/31/2013
• Est. Priority Date: 08/03/2009
• Status: Expired due to Fees

• Current Assignee: Arconic Technologies LLC (Arconic Corp.)
• Original Assignee: Alcoa Incorporated (Howmet Aerospace, Inc.)
• Inventors: Kahn, Jay A., Nintzel, Grant, Belnap, Craig, Zediak, Clinton, Keener, John, Bell, James, Askin, Albert L., Kolek, Paula L., Skiles, Jean Ann, Biehlmann, Yves
• Primary Examiner(s): WEDDLE, ALEXANDER MARION
• Application Number:
  US12/569,673
• Publication Number:
  US 20110027485A1
• Time in Patent Office: 1,554 Days
• Field of Search: 427/331, 427/419.1, 427/419.2, 427/419.3, 427/428.01, 427/428.08
• US Class Current: 427/419.3
• CPC Class Codes: B05D 1/28 performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
• CPC Class Codes: B05D 2202/25 based on Al
• CPC Class Codes: B05D 5/08 to obtain an anti-friction or anti-adhesive surface rendering particulate materials free-flowing in general, e.g. making them hydrophobic B01J2/30
• CPC Class Codes: B05D 7/56 Three layers or more
• CPC Class Codes: C09D 5/1618 inorganic
• CPC Class Codes: C09D 5/1693 as part of a multilayer system
• CPC Class Codes: C23C 26/00 Coating not provided for in groups C23C2/00 - C23C24/00
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D

Abstract

A methods, apparatus and compositions for producing colored, self-cleaning substrates by roll coating are provided. The roll coated, colored, self-cleaning substrates retain the predetermined color and a predetermined gloss of the colored coating, thereby facilitating their use in architectural applications. The roll coated, colored, self-cleaning substrates may be iridescent-free.

Claims

1. A method comprising:

(a) first producing a colored aluminum sheet product, the first producing step comprising;

(i) first roll coating a colored coating liquid onto an aluminum alloy sheet; and

(ii) first converting the colored coating liquid into a colored layer, wherein the colored layer is located on an outer surface of the aluminum alloy sheet;

(b) second producing an intermediate aluminum sheet product, the second producing step comprising;

(i) second roll coating an inorganic barrier coating liquid onto at least a portion of the colored layer of the colored aluminum sheet product, wherein the inorganic barrier coating liquid is in the form of an aqueous solution comprising silica; and

(ii) second converting the inorganic barrier coating liquid into an inorganic barrier layer, wherein, after the second converting step, the inorganic barrier layer is located on at least a portion of the colored layer; and

(c) third producing a colored self-cleaning aluminum sheet product, the third producing comprising;

(i) third roll coating a portion of an aqueous-based self-cleaning coating precursor liquid onto at least a portion of the inorganic barrier layer of the intermediate aluminum sheet product;

wherein, the self-cleaning coating liquid includes photocatalytically active semiconductor particles;

(ii) third converting the aqueous-based self-cleaning coating precursor liquid into a self-cleaning layer, wherein, after the third converting step;

(A) the self-cleaning layer is located on at least a portion of the inorganic barrier layer;

(B) the photocatalytically active semiconductor particles are uniformly dispersed throughout the self-cleaning layer.

2. The method of claim 1, wherein the third producing step comprises:

agitating the aqueous-based self-cleaning coating precursor liquid inside a coating reservoir; and

applying the self-cleaning precursor liquid to the inorganic barrier layer.

3. The method of claim 2, wherein the agitating step comprises continuous agitation.